Al-Infiraj Oil Group perceives the importance of Cathodic Protection for the foundations', structures', buildings' and engineering annexes' infrastructures in all of the industrial fields. The Group, as well, perceives the security and guarantee factors that this mean provides to improve the performance and increase the operation life time of such installations. Therefore and relying on its own capabilities, Al-Infiraj Group has designed and executed high efficiency Cathodic Protection Systems of competitive costs. Many State and private bodies were supplied with such systems, wherein they proved successful and efficient performance.

Al-Infiraj Oil Group is, right now, considered the leading entity in Iraq in the field of Design and Manufacture of Cathodic Protection Systems, in particular, that system that depends on Ferro-Silicon Anode which is mainly composed of the following components:

Permanent Reference Electrode

Introduction
There are many types (according to use and purpose) of permanent reference electrodes that are used in the Cathodic Protection, the most important is the copper – copper sulfate (saturated) electrode which is buried underground to protect the pipeline. This type offers the Corrosion Engineers satisfactory site voltage measures in comparison with the surface electrodes. The electrode is preserved in a packing to maintain constant humidity for around twenty years.

Types of Permanent Electrodes:
The most important types are:

1. Copper – Copper sulfate (Cu – CuSO4)
2. Silver – Silver Chloride (Ag – AgCl).
3. Zinc – Zinc Sulfate (Zn – ZnSO4).

Portable Reference Electrode

Introduction

For the purpose of measuring the electrical potential changes around the fixtures to be protected from corrosion a reference electrode is used. This reference electrode is half cell that gives constant voltage to measure the change of the voltage required for cathodic protection.

Types of Reference Electrodes:
There are many types (according to their use in control or test) of reference electrodes:

1. Cu/CuSO4.
2. Ag/AgCl.
3. Ag/AgCl/KCl.
4. Zn/ZnSO4.

The Manufacture of Electrode:

• Components:
  The portable Reference Electrode is composed of several parts:
  1. First:  high purity Copper shaft.
  2. Second: High purity and transparency poly carbonate tube (perspect). Upper side indented to a certain depth and the other side is opened.
  3. Third: The upper cover: made of poly carbonate, indented to close the upper tube opening in "Second". This cover is center-drilled.
     The lower cover: made of wood with certain porosity. O-ring is to be placed in the middle as insulator.
  4. Fourth:        Single phase plug fixed at the opening of the upper cover.
  5. Fifth:           Single electrical wire, of various lengths, upon requirement.
  6. Sixth:           Copper Sulfate (CuSO4).
• Raw Materials:
  
  1. First: High purity and transparency poly carbonate tube.
  2. Second: High purity copper shaft.
  3. Third: Wooden shaft.
  4. Fourth: O-ring.
  5. Fifth: Single phase plug.
  6. Sixth: Copper Sulfate (CuSO4).
  S
  7. eventh: Single phase wire.
• Devices and equipments used in the manufacturing process:
  
  1. First: Medium size lathe.
  2. Second: Vertical Drill.
  3. Third: Hand tools and fining materials.

Kirk Cell

In order to obtain sound cathodic protection, Kirk Cell should be used. This cell works as electrochemical switch to provide DC voltage to the cathodic protection circuit. It consists of two groups of stainless steel plates immersed in potassium hydroxide electrolyte solution.

Components and Parts:
The Kirk Cell is manufactured at Tulu' Al-Shams Co. from home raw materials, it was successfully used in work sites.
Every single cell consists of the following materials and parts:

1. Container: Made of glass.
2. Upper cover: Made of tefelon has two opposite openings, in addition to a third opening (closed by cork) for filling the cell.
3. Fixing Screw: Made of brass for conducting current between the plates and the electrical circuit.
4. Plates Set: 8 stainless steel plates are used. The plate is drilled in two positions in order to be fixed by two screws. Plastic washer is placed between every two plates as insulator. The plate set is fixed to the upper cover by two brass screws from top.
5. Potassium hydroxide electrolyte solution.

Devices and Equipments Used:
For the manufacture of single Kirk Cell, the following is required:

1. Manual or Hydraulic plates cutter.
2. Lathe for the production of fixing screws and nuts.
3. Electrical test apparatuses (voltmeter, ammeter… etc.).
4. Manual or electrical drill.
5. Mechanical hand tools.

Transformer – Rectifier Unit

To operate and control the system, Transformer – Rectifier Unit is used; it should be durable against different working circumstances and capable of protecting the system practically.
There are several types of these units, such as air cooled and oil. Selection depends on the designer, the environmental circumstances around the system and the cost.

The Current System:
Through the technical experience of the Company, the control system of Transformer – Rectifier Unit is designed and manufactured from home raw materials according to the design characteristics required by the beneficiary. It has been used at the field site and proved its high efficiency; therefore vast numbers of this system has been supplied to various bodies. The system consists of the following main parts:

1. Rectangular section reservoir, filled with oil up to a certain height, contains a movable cover with a filling / emptying opening, oil level meter and thermometer. Inside there are holder to fix the transformers and the bridge.
2. Protection board to protect the electrical parts such as meters, circuit breakers, fuses and indication light. It has the following electrical parts:
   • Voltmeter.
   • Clamp meter.
   • Ammeter.
   • Circuit breaker.
   • Indication light.
   • Selector switch.
   • Fuses.
3. Primary transformer.
4. Secondary Transformer.
5. Bridge.
6. Transformers cooling oil.
7. Base to carry the system, consists of channel steel.
8. Cooling fins.
9. Double gate to protect the electrical board against climate circumstances.

Silicon Iron Anodes

Introduction:
Silicon Iron Anode is considered as one of the most widely used anodes in Cathodic Protection to protect land-installations and underground pipelines; it gives high protection for more than 20 yrs. These anodes are manufactured according to BS 1591 or ASTM A518 using ground sand moulds casting method and taking the shape of rods, or pipes using centrifugal casting. Anodes are used in various circumstances; such as dry, humid, maritime and sweet water areas and in the natural soil as well. The chemical composition of anode alloy is as follows:

Anode Components and Parts:
The anode is manufactured from the above raw materials. First the materials are mixed according to the weight ratio of each component and then the desired dimensions, diameters and weights are calculated. The cable junction point to the anode is fixed by Lead insolated by Epoxy and a sleeve as final insulation. The cable is insolated by PVC, XLPE or any available.

Flange Insulation

In order to secure good performance of pipes transporting various gases and liquids, protect the environment and prevent leakage (through flanges in particular) and to prevent corrosion that reduces the system lifetime, several flange insulation technologies are applied using single and double Flange Insulation Kit. The kit consists of the following parts:

• First: Insulation Gasket.
• Second: Insulation Sleeve.
• Third: Insulation Washer.
• Fourth: Steel Washer.
• Fifth: Bolt, Stud and Nut.

The Insulation Kit is manufactured according to the international standards. It should resist moisture, operate at high temperatures and maintain its chemical composition, electrical resistance and other electrical and mechanical specifications. Standards adopted are (American Standards Association, ASA) and (American National Standards Institute, ANSI).

Specifications of various Kit's materials:

1. Insulation Gasket: Normally made of Fabric-Reinforced Phenolic in various types and sizes, inter-alia, type D, E and F, according to use and flange type. Type D is used for Ring Groove, type E is used for insulating the whole surface area of the flange with the same holes of the flange whilst type F is the same as E but with no holes. Various types of gaskets are available according to various diameters and thicknesses.
2. Insulation Sleeve: There are two sleeve types; washer and washer less sleeve, every single type is used with a certain flange type and shape. The sleeve of HDPE in various sizes and thicknesses. Other types of sleeves are made of other materials, such as phenolic, mylor and else, according to their use. The chemical and physical specifications adopted in the sleeves manufacture are standard as concerned with electrical resistance, dielectric strength, moisture absorbing and maximal bearing of working temperature. These specifications are variable according to the raw materials the sleeve is made of.
3. Stud and Steel Washer: Made of steel of various diameters and dimensions according to use.

Method of requesting the Kit:
To request certain Kit Requisition, the following items are mentioned to select the most suitable:

1. Gasket type (D, E or F).
2. Flange diameter, size and exerted pressure, as shown in the attached table.
3. Sleeve Washer type (Single Washer / SW or Double Washer / DW).
4. Raw materials the sleeve is made of.
5. Material or liquid passes through the flange or pipe.

Home manufacture of Kit's parts:
The gasket and the sleeve were home manufactures from Phenolic and HDPE and other raw materials available at the home markets. The dimensions and specifications were according to the international standards and as per the beneficiary requirements. These materials were successfully used.